Construction block

ABSTRACT

A construction block is provided that includes at least one base member that includes a plurality of lower side wall receptacles. The construction block further includes a plurality of side wall assemblies. Each of the side wall assemblies includes a plurality of interconnected panels. Each of the panels is hingedly connected to each adjacent one of the panels of the respective one of the side wall assemblies. Each of the side wall assemblies defines a hollow load chamber having an open top and an open bottom. At least some of the panels of each of the side wall assemblies are angled relative to one another. Each of the lower side wall receptacles receives one of the side wall assemblies.

CROSS REFERENCES

This application claims the priority benefit of U.S. Provisional PatentApplication Ser. No. 60/875,332, “Building Block”, filed Dec. 15, 2006,which is expressly incorporated by reference herein in its entirety.

TECHNICAL FIELD

This application is related to structural components, and moreparticularly, to construction blocks.

BACKGROUND

Global terrorism, which has been steadily and significantly increasing,has created an urgent need for more effective and rapidly deployablemeans of protecting military and civilian personnel and a wide varietyof government, commercial and private sector structures or other assets.This is particularly true in war zones where serious injury or death ofmilitary and civilian personnel can result from weapons that caninclude, but are not limited to: improvised explosive devices (IEDs);mortar/rocket propelled grenades (RPGs); small arms fire; and shrapnelfrom blasts against various structures such as concrete walls. Examplesof military applications for such effective and rapidly deployableprotection can include: base camps; soldier fighting positions; commandposts; check point security; perimeter security and revetments aroundmilitary assets, for example, aircraft; as well as temporary structuralrepairs. Examples of government and private sector applications ofeffective protection, in view of potential terrorist attacks or naturaldisasters such as hurricanes, can include government or commercialbuildings, flood mitigation, disaster relief walls and shelters, andhistoric landmarks.

Known means of protection against hostile forces in war zones, as wellas terrorist attacks and natural disasters include walls or revetmentsconstructed of sandbags. Although effective in some instances,construction of such walls or revetments can be very labor intensive andthey can become unstable over time. Also, in most cases the walls orrevetments are not suitable for supporting additional structures.Further, the choice of ballast material that can be used is somewhatlimited and the walls or revetments can be time consuming todisassemble.

Other conventional devices used to provide protection against varioussimilar threats include walls constructed of baskets that are made fromgalvanized steel weld mesh. The interior of the grid-like baskets can belined with water permeable, geotextile felt material to retainrelatively smaller ballast material such as gravel, sand and fines. Suchbaskets are typically relatively large and often require the use ofheavy earth moving equipment and a skilled labor force at the site.

SUMMARY

A collapsible side wall assembly is provided for use in a constructionblock and includes a plurality of interconnected panels, with each ofthe panels being disposed intermediate a pair of the panels and hingedlyconnected to each one of the pair of panels. The plurality ofinterconnected panels are movable between a collapsed configuration andan erected configuration. The plurality of interconnected panels definea hollow load chamber having an open top and an open bottom when theplurality of interconnected panels are in the erected configuration.Each of the panels includes a central portion having an inner surfaceand a generally planar outer surface and further includes first andsecond sides and first and second end flanges. The central portionextends between the first and second sides and between the first andsecond end flanges. The generally planar outer surfaces of the centralportions of at least some of the panels are angled relative to oneanother when the plurality of interconnected panels are in the erectedconfiguration. The first end flange and the second end flange are offsetinwardly from the generally planar outer surface of the central portion,for at least some of the panels.

A collapsible side wall assembly is provided for use in a constructionblock and includes a plurality of interconnected panels, with each ofthe panels being disposed intermediate a pair of the panels and hingedlyconnected to each one of the pair of panels. Each of the panels includesa central portion having an inner surface and an outer surface and eachof the panels includes a thermoplastic material. The plurality ofinterconnected panels are movable between a collapsed configuration andan erected configuration. The plurality of interconnected panels definea hollow load chamber having an open top and an open bottom when theplurality of interconnected panels are in the erected configuration. Theouter surfaces of the central portions of at least some of the panelsare angled relative to one another when the plurality of interconnectedpanels are in the erected configuration.

A construction block is provided and includes at least one base memberhaving a plurality of lower side wall receptacles and a plurality ofside wall assemblies, with each of the side wall assemblies including aplurality of interconnected panels. Each of the panels are hingedlyconnected to each adjacent one of the panels of a respective one of theside wall assemblies. Each of the side wall assemblies defines a hollowload chamber having an open top and an open bottom. At least some of thepanels of each of the side wall assemblies are angled relative to oneanother. The construction block further includes at least one lidincluding a plurality of upper side wall receptacles. Each of the lowerside wall receptacles receives a respective one of the side wallassemblies and each of the upper side wall receptacles receives arespective one of the side wall assemblies.

A structure is provided that is made from a kit of construction blockcomponents. The kit includes a plurality of base members and a pluralityof collapsible side wall assemblies. Each of the collapsible side wallassemblies includes a plurality of hingedly interconnected panels andeach of the collapsible side wall assemblies is movable between acollapsed configuration and an erected configuration. The collapsibleside wall assemblies define, in the erected configuration, a hollow loadchamber having an open top and an open bottom. The structure includes abase layer including a first plurality of the base members disposedadjacent to one another and further includes a plurality of thecollapsible side wall assemblies, in the erected configuration. Each ofthe base members of the first layer releasably engages at least one ofthe erected side wall assemblies.

A structure is provided and includes a base layer including a firstplurality of construction blocks which are positioned adjacent oneanother and a second layer including a second plurality of constructionblocks which are positioned adjacent one another. Each of theconstruction blocks of the second plurality of the construction blocksis positioned on top of and releasably engaged with at least one of theconstruction blocks of the first plurality of the construction blocks.Each of the construction blocks of the first and second pluralities ofthe construction blocks includes a lid, a base member and a plurality ofside wall assemblies. Each of the side wall assemblies of the first andsecond pluralities of the construction blocks includes a plurality ofhingedly interconnected panels. Each of the panels are hingedlyconnected to each adjacent one of the panels of the respective one ofthe side wall assemblies of the first and second pluralities of theconstruction blocks. Each of the side wall assemblies of the first andsecond pluralities of the construction blocks defines a hollow loadchamber having an open top and open bottom. Al least one of the panelsof each of the side wall assemblies of the first and second pluralitiesof the construction blocks includes a thermoplastic material.

A method of building a modular structure is provided and includesproviding a kit of construction block components which includes aplurality of base members and a plurality of collapsible side wallassemblies. Each of the side wall assemblies includes a plurality ofhingedly interconnected panels and the side wall assemblies are movablebetween a collapsed configuration and an erected configuration. The sidewall assemblies define, in the erected configuration, a hollow loadchamber having an open top and an open bottom. The method furtherincludes building a base layer of the structure. Building the base layerincludes arranging a plurality of the base members adjacent to oneanother. Building the base layer further includes releasably engagingeach of the base members of the base layer with at least one of the sidewall assemblies of the kit, in the erected configuration. Building thebase layer further includes at least partially filling the load chambersof the erected side wall assemblies of the base layer of the structurewith ballast material.

A method of manufacturing a kit of construction block components isprovided and includes forming a plurality of panels from a thermoplasticmaterial, with the panels being configured to create at least one sidewall assembly. The method further includes forming a base member from athermoplastic material, with the base member being configured toreleasably engage the at least one side wall assembly. The methodfurther includes forming a lid from a thermoplastic material, with thelid being configured to releasably engage the at least one side wallassembly.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features and advantages of the present invention will becomebetter understood with regard to the following description, appendedclaims and accompanying drawings wherein:

FIG. 1 is a front perspective view of a construction block according toone embodiment.

FIG. 2 is an exploded assembly view of the construction block shown inFIG. 1.

FIG. 3 is a front elevation view of the construction block shown inFIGS. 1-2.

FIG. 4 is a rear elevation view of the construction block shown in FIGS.1-3.

FIG. 5 is a longitudinal cross-sectional view taken along line 5-5 inFIG. 3.

FIG. 6 is a front elevation view of a single panel according to oneembodiment, that can be used in the side wall assemblies of theconstruction block shown in FIGS. 1-4.

FIG. 7 is a rear elevation view of the panel shown in FIG. 6.

FIG. 8 is an exploded assembly view of two panels according to theembodiment shown in FIGS. 6 and 7, and a hinge pin to illustrate thehinged connection of the two panels.

FIG. 9 is a transverse cross-sectional view taken along line 9-9 in FIG.6.

FIG. 10 is a rear elevation view of a panel according to anotherembodiment.

FIG. 11 is a transverse cross-sectional view taken along line 11-11 inFIG.

FIG. 12 is a transverse cross-sectional view similar to FIG. 11 of apanel according to another embodiment.

FIG. 13 is a transverse cross-sectional view similar to FIG. 11 of apanel according to another embodiment.

FIG. 14 is a perspective view of one of the collapsible side wallassemblies shown in FIGS. 1-4, with the side wall assembly being shownin an erected configuration and including eight interconnected panels.

FIG. 15 is a transverse cross-sectional view taken along line 15-15 inFIG. 14.

FIG. 16 is a transverse cross-sectional view similar to FIG. 15illustrating a collapsible side wall assembly according to anotherembodiment.

FIG. 17 is a transverse cross-sectional view similar to FIG. 15illustrating a collapsible side wall assembly according to anotherembodiment.

FIG. 18 is a transverse cross-sectional view similar to FIG. 15illustrating a collapsible side wall assembly according to anotherembodiment.

FIG. 19 is a plan view of the collapsible side wall assembly shown inFIGS. 14 and 15, with the assembly shown in a partially collapsedconfiguration.

FIG. 20 is a plan view of the side wall assembly shown in FIG. 19 withthe side wall assembly shown in a completely collapsed configuration.

FIG. 21 is a top plan view of the two side wall assemblies of theconstruction block shown in FIGS. 1-4.

FIG. 22 is a top plan view of the base member of the construction blockshown in FIGS. 1-4.

FIG. 23 is a bottom plan view of the base member shown in FIG. 22.

FIG. 24 is a top plan view of the lid of the construction block shown inFIGS. 1-4.

FIG. 25 is a bottom plan view of the lid shown in FIG. 24.

FIG. 26 is a perspective view, partially broken away, illustrating anapplication of structures made from construction block components inaccordance with one embodiment.)

FIG. 27 is a perspective view of a kit of construction block components,with like components stacked on top of one another on a pallet.

FIG. 28 is a perspective view of the two side wall assemblies of theconstruction block shown in FIGS. 1-4.

FIG. 29A is a plan view of three base members of the base layer of oneof the walls shown in FIG. 26.

FIGS. 29B and 29C are plan views illustrating alternate angularorientations between adjacent base members that can be used instructures made from construction block components according to certainembodiments.

FIGS. 30-32 are perspective views further illustrating the constructionof one of the walls shown in FIG. 26.

FIG. 33 is a perspective view similar to FIG. 32 illustrating astructure according to another embodiment.

FIG. 34 is a perspective view of a structure according to anotherembodiment.

FIG. 35 is a front elevation view, similar to FIG. 3, illustrating aconstruction block according to another embodiment.

FIG. 36 is a perspective view, partially broken away, of the two sidewall assemblies of the construction block shown in FIG. 35.

FIG. 37 is a plan view of a strip of hingedly interconnected panelsaccording to one embodiment, prior to final forming, that can be used toform the side wall assemblies shown in FIG. 36.

FIG. 38 is a side view of the panels shown in FIG. 37 furtherillustrating the hinges between adjacent panels.

FIGS. 39A-39F illustrate a series of steps that can be used to fold thestrip of panels shown in FIGS. 37 and 38 into the two side wallassemblies shown in FIG. 37.

FIG. 40 is a front perspective view of a construction block according toanother embodiment.

FIG. 41 is a rear perspective view of a construction block according toanother embodiment.

DETAILED DESCRIPTION

Referring to the drawings, like numbers (e.g., 24, 124, 224) canindicate the same or corresponding elements throughout the views. FIGS.1-9, 14, 15 and 19-25 illustrate a construction block 10 according toone embodiment. Construction block 10 can include two side wallassemblies 12, as shown in FIGS. 1-4. The side wall assemblies 12 can besecured to one another. The side wall assemblies 12 can be secured toone another with the use of connecting members 14, which can be bars,plates and the like, and conventional fasteners, such as bolts 16 andnuts 18 shown in FIGS. 2 and 21, or by any other suitable means. Theconstruction block 10 further includes a lid 20 and a base member 22,with each of the side wall assemblies 12 releasably engaged with boththe lid 20 and the base member 22, as subsequently described in greaterdetail. Construction blocks according to other embodiments (not shown)can include a single side wall assembly 12 or more than two of the sidewall assemblies 12 that can be interconnected with one another. Suchconstruction blocks would include base members and lids configured topermit releasable engagement with all of the included side wallassemblies 12.

Each of the side wall assemblies 12 includes a plurality ofinterconnected panels 24. As shown in FIGS. 19 and 20, the side wallassemblies 12 can be collapsible side wall assemblies and the pluralityof panels 24 of each side wall assembly 12 can be hingedlyinterconnected. FIG. 19 illustrates one of the side wall assemblies 12in a partially collapsed configuration, and FIG. 20 illustrates one ofthe side wall assemblies 12 in a completely collapsed configuration,which can be a generally flattened configuration. FIG. 14 illustratesone of the side wall assemblies 12 in the erected configuration. Sidewall assemblies 12 are in the erected configuration when engaged withlid 20 and base member 22 as shown in FIGS. 1-4. Each panel 24, of eachside wall assembly 12, is disposed intermediate a pair of the panels 24and is hingedly connected to each adjacent panel 24. For example, asshown in FIG. 3, panel 24 a of side wall assembly 12 i is disposedintermediate panels 24 b and 24 c and is hingedly connected to each ofpanels 24 b, 24 c. Similarly, panel 24 d of side wall assembly 12 ii isdisposed intermediate panels 24 e and 24 f and is hingedly connected toeach of panels 24 e, 24 f. The hinged connection between a pair ofadjacent panels 24 may be further appreciated with reference to FIGS.6-8.

As shown in FIGS. 6-8, each panel 24 includes a first side 26, a second,opposite side 28 and a central portion 30. Each panel 24 can also have afirst end flange 32 and a second, opposite end flange 34. Theconfigurations of end flanges 32 and 34 can be the same or different.The central portion 30 can extend continuously between the first 26 andsecond 28 sides and continuously between the first 32 and second 34 endflanges and each panel 24 can be solid. Central portion 30 has an innersurface 36 and an outer surface 38 that can be generally planar.

Each panel 24 can include a first plurality of female hinge members 40extending from side 26 of panel 24 and a second plurality of femalehinge members 42 extending from side 28 of panel 24. The female hingemembers 40 can be misaligned with the female hinge members 42 so thatthe female hinge members 40 of one panel 24 can be juxtaposed with thefemale hinge members 42 of an adjacent panel 24, when the panels 24 ofeach side wall assembly 12 are hingedly interconnected.

Each side wall assembly 12 can include a plurality of male hinge members44 that can be pins, rods, bolts and the like (FIG. 8). Each of thefemale hinge members 40 and each of the female hinge members 42 caninclude an aperture extending therethrough that is configured to receiveone of the male hinge members 44. During assembly, each male hingemember 44 can be inserted through the female hinge members 40 of onepanel 24 and through the female hinge members 42 of an adjacent panel24, as illustrated in FIG. 8 with respect to one pair of panels 24. Malehinge member 44 can be made of a variety of materials including, but notlimited to: various metals and metal alloys; various plastic materials;fiberglass; and fiber-reinforced epoxy composites.

In another embodiment (not shown), the panels of each side wall assemblycan be hingedly interconnected using hinge members having a differentconfiguration. For example, each panel can include a plurality of spacedmale hinge members integral with one side of the panel and a pluralityof spaced, mating female hinge members integral with the opposite sideof the panel, in lieu of the female hinge members 40, 42. The male andfemale hinge members of each panel can be misaligned so that the malehinge members of each panel can engage the female hinge members of anadjacent panel. In this embodiment, the male hinge members 44 are notrequired.

End flange 32 can be offset inwardly from the generally planar outersurface 38 of the central portion 30 of panel 24 as shown in FIGS. 6, 8and 21. Similarly, end flange 34 can be offset inwardly from outersurface 38. The offset configuration of flanges 32 and 34 can facilitatethe releasable engagement of the side wall assemblies 12 with lid 20 andbase member 22 and can permit the outer surface 38 of panels 24 to beflush with outer surfaces of lid 20 and base member 22 as shown in FIGS.1, 3 and 4 and subsequently described further. End flanges 32 and 34 caninclude lead-in chamfers (not shown) to facilitate the releasableengagement of the side wall assemblies 12 with lid 20 and base member22. It should be appreciated that side wall assemblies (not shown) canbe releasably engaged with lid 20 and base member 22 using flangeshaving different configurations than those of flanges 32, 34. Also, itshould be appreciated that side wall assemblies (not shown) canreleasably engage lid 20 and base member 22 without the use of flanges.As one example, the male hinge members 44 can be sized so that theyextend above and below panels 24 and engage mating receptacles (notshown) in the lid 20 and base member 22. Also, rods, pins or the likecan protrude from lid 20 and base member 22 and engage matingreceptacles in side wall assembly 12.

Panels 24 can be made of a thermoplastic material, which can be anenergy absorbing thermoplastic material. For example, panels 24 can bemade of a variety of polymers including various ceramifying polymers.Examples of suitable polymers that can be used include, but are notlimited to: acrylonitrile butadiene styrene (ABS); high impact plastics(HIPs), for example high impact polystyrene; and various ceramifyingpolymers, for example ceramifying polyvinyl chloride (PVC) andceramifying ethylene propylene diene monomer (EPDM). The butadienecomponent of ABS is a “rubber-like” component that can provide impactabsorption, anti-fragmentation advantages and can exhibit a self-healingcharacteristic, which can facilitate retaining ballast material assubsequently described. High impact plastics can result in manufacturingcost advantages, for example when panels 24 are mass produced. Theceramifying polymers can have superior fire resistance properties. Itshould be understood that the advantageous properties of the exemplarythermoplastic materials are not limited to the particular propertiesdescribed above. Panels 24 can also include various performanceenhancing additives mixed with the base material of the panels 24. Forexample, an ultra violet (UV) and/or a fire resistant material can beadded to a thermoplastic material or can be a coating, which can bespayed onto the thermoplastic material to form panels 24.

Panels (e.g., 24) can be formed, for example, by injection molding,thermoforming, or extrusion. When the panels are molded, the panels caninclude one or more ribs, a network or grid of ribs, or otherreinforcement members protruding from the inner side of the panels toprevent or at least minimize warpage of the panels due to the moldingprocess and/or during use of the panels and to enhance the strength ofthe panels. For example, FIGS. 10 and 11 illustrate a panel 124 that canincorporate a network of ribs. Panel 124 includes a central portion 130having an inner surface 136 and an outer surface 138, which can be agenerally planar outer surface. Panel 124 can include end flanges 132and 134 that can be offset inwardly from the generally planar outersurface 138. Panel 124 can include a plurality of female hinge members140 and a plurality of female hinge members 142, extending from oppositesides of panel 124. As shown in FIG. 10, panel 124 can include a network150 of ribs that can include a plurality of longitudinally extendingribs 152 and a plurality of transversely extending ribs 154 that canintersect ribs 152, for the purpose of preventing or at least minimizingwarpage of panel 124 during the molding process and/or during use ofpanels 124 and to enhance the strength of panels 124.

Panels can also include a coating applied to the outer surface of thepanels. For example, panel 124 can include a coating 160 applied to theouter surface 138 of central portion 130 as shown in exaggerated scalein FIG. 11. Coating 160 may be applied for a variety of purposes, forexample to enhance one or more properties of the respective panels, suchas anti-fragmentation, UV and heat resistance properties. Examples ofsuitable materials for coating 160 include, but are not limited to:ceramifying polymers (when the base material of panel 124 is not aceramifying polymer), having rough textures; elastomeric polymers suchas Line-X™; and Teflon® resins. Furthermore, coating 60 can also be arelatively thin metal film-which can enhance the anti-EMF(electromagnetic field) properties of the respective panels to preventor at least inhibit wireless directed electromagnetic energy emanatingfrom a weapon from passing through the panels. Coatings may be appliedto specific areas or the entire surface of panel 124 depending on needs.

Panels such as panel 224 shown in FIG. 12 can be thermoformed from athermoplastic material, which can be an energy-absorbing thermoplasticmaterial. Panel 224 includes first 226 and second 228 layers ofthermoplastic material, created by the thermoforming process. Panel 224can include first 240 and second 242 female hinge members. Panels can beextruded from a thermoplastic material, for example panel 324 shown inFIG. 13. Panel 324 can include an outer portion 326 and an inner portion328 of thermoplastic material, which can be an energy absorbentthermoplastic material. The outer 326 and inner 328 portions can includenotches configured to receive a reinforcement member 329 between outer326 and inner 328 portions. Panel 324 can include female hinge members340, 342. Reinforcement member 329 can be made of various materials thatcan include a metal, a metal alloy, a ceramic, a polymer (provided it isdifferent than the base material of the panel 324, which can be apolymer) and a high-tensile strength fabric, such as Kevlar™.Reinforcement member 329 can enhance the structural and anti-penetrationproperties of panel 324. Reinforcement members can be included in otherpanels. For example, reinforcement members can be embedded in thethermoplastic material of panels 24 and 124.

The collapsible side wall assemblies 12 can be movable between thecollapsed configuration, shown in FIG. 20 and the erected configurationshown in FIG. 14, provided the assemblies 12 are not engaged with lid 20and base member 22. Side wall assemblies 12 remain in the erectedconfiguration, shown in FIGS. 1-4, when side wall assemblies 12 areengaged with lid 20 and base member 22. The ability to collapse sidewall assemblies 12 allows assembled side wall assemblies 12 to bestacked on top of one another, as shown in FIG. 27, which facilitatesshipment of side wall assemblies 12 and can facilitate the rapiddeployment of side wall assemblies 12 when required.

As shown in FIG. 14, the plurality of interconnected panels 24 of sidewall assembly 12 define a hollow load chamber 70 having an open top 72and an open bottom 74 when side wall assembly 12 is in the erectedconfiguration. Load chamber 70 is configured to receive virtually anyballast material. At least some of the panels 24 of the side wallassemblies 12 can be angled relative to one another. For example, asshown in FIGS. 1-4, 14, 15 and 21, side wall assembly 12 includes eightof the panels 24, with all of the panels 24 angled relative to oneanother when side wall assembly 12 is in the erected configuration. Inother embodiments, for example construction block 900 shown in FIG. 40,some of the included panels can be parallel to one another, with othersbeing angled relative to one another, when side wall assemblies 912 arein the erected configuration.

As shown in the transverse cross-sectional view illustrated in FIG. 15(or in a top or bottom plan view), the generally planar outer surfaces38 of the central portions 30 of the panels 24 can cooperate to define apolygon when side wall assembly 12 is in an erected configuration. Thepolygon can be an octagon as shown in FIG. 15.

FIG. 16 illustrates a side wall assembly 412 according to anotherembodiment. Assembly 412 includes six panels 424, which can have thesame or different widths than panels 24 and can otherwise be the same aspanels 24. As shown in FIG. 16, the generally planar outer surfaces 438of the central portions 430 of panels 424 can cooperate to define ahexagon when side wall assembly 412 is in an erected configuration.

FIG. 17 illustrates a side wall assembly 512 having two panels 524 andtwo panels 624. Panels 524 and 624 can have different widths and canhave the same or different widths than panels 24 and can otherwise bethe same as panels 24. As shown in FIG. 17, the generally planar outersurfaces 538 of the central portions 530 of panels 524 cooperate withthe generally planar outer surfaces 638 of the central portions 630 ofpanels 624 to define a rectangle when side wall assembly 512 is in anerected configuration.

FIG. 18 illustrates a side wall assembly 612 according to another.embodiment. Assembly 612 includes four of the panels 624. As shown inFIG. 18, the generally planar outer surfaces 638 of the central portions630 of panels 624 cooperate to define a square when side wall assembly612 is in the erected configuration. Side wall assemblies can havedifferent numbers of included panels and can define polygons havingdifferent shapes than those illustrated in FIGS. 15-18.

Referring to FIGS. 22 and 23, base member 22 includes an upper surface80 and a lower surface 82 and can include a lower boundary flange 84.The upper surface 80 and the lower boundary flange 84 can cooperate todefine a pair of lower side wall receptacles 86. Each of the receptacles86 can be configured to receive one of the side wall assemblies 12. Thetwo receptacles 86 can be symmetrically disposed about a lateralcenterline axis 88 of base member 22. Base member 22 can further includea pair of apertures 90, with one of the apertures 90 in each lower sidewall receptacle 86. Apertures 90 are shown to have a polygonal shape butcan have any of a variety of other suitable shapes. The lower surface 82can define a pair of recessed ledges 92, which can have a polygonalshape or any other suitable shape. Base member 22 can be made of athermoplastic material, including any of the materials describedpreviously that can be used to form panels 24. Base member 22 can bemolded, for example by injection molding. Base member 22 can also bethermoformed.

Referring to FIGS. 24 and 25, lid 20 includes an upper surface 94, alower surface 96 and can include an upper boundary flange 98. The lowersurface 96 and upper boundary flange 98 of lid 20 can cooperate todefine a pair of upper side wall receptacles 100, each configured toreceive one of the side wall assemblies 12. Each of the receptacles 100can be symmetrically disposed about a lateral centerline axis 101 of lid20. Lid 20 can further include a pair of protrusions 102, extendingupwardly from the upper surface 94 of lid 20. Protrusions 102 can have apolygonal shape or any other suitable shape and the shape of protrusions102 can be complementary with the shape of the recessed ledges 92 ofbase member 22 so that each protrusion 102 of lid 20, of a relativelylower layer of a structure according to some embodiments, can nestwithin one of the recessed ledges 92 of a base member 22 of a relativelyhigher layer of the structure that is vertically adjacent to therelative lower layer, as explained further with reference to FIGS. 31and 32. In other embodiments, a base member (not shown) can beconfigured to include a pair of protrusions that can be similar toprotrusion 102 of lid 20, extending downwardly from a lower surface ofthe base member. In such other embodiments a lid (not shown) can beconfigured to have an upper surface that can define a pair of recessedledges, that can be similar to recessed ledges 92 of base member 22,with the recessed ledges having a shape that is complementary with theshape of the protrusions of the base member so that the protrusions ofthe base member can nest within the recessed ledges of a correspondinglid of a vertically adjacent and lower layer of a structure. Also, itmay be appreciated that base member 22 can have a single recessed ledge92 or more than two of the recessed ledges 92 and that lid 20 can have asingle protrusion 102 or more than two of the protrusions 102.

Each protrusion 102 can include a solid central portion 104 (FIG. 24).Alternatively, the central portion 104 can be removed to create anaperture 105 (FIGS. 31, 32 and 34), for example when lids 20 are used toconstruct a modular structure having multiple layers or courses, so thatload chambers 70 of vertically adjacent layers of the structure cancommunicate with one another. In one embodiment, perforationssurrounding at least a portion of central portion 104 can be used tofacilitate removal of central portion 104.

Lid 20 can be made of a thermoplastic material, including any of thematerials described previously that can be used to form panels 24. Lid20 can be molded, for example by injection molding, and can also bethermoformed.

FIG. 26 illustrates one application of certain structures. For example,as shown in FIG. 26, front wall 702 and rear wall 704, as well as sidewalls 706, 708, 710 and 712 can be used to limit the vulnerability ofbuilding 700 to explosive ordinance and other threats from hostileforces. Walls 706 and 708 can be connected to front wall 702 and walls710 and 712 can be connected to rear wall 704. The walls 702, 704, 706,708, 710, and 712 can be constructed using the modular components ofconstruction blocks. The construction of wall 702 may be appreciatedwith reference to FIGS. 26-32 that illustrate the construction of aportion of wall 702. Wall 702 can be constructed from a kit ofcomponents of construction blocks 10, for example, which can includeside wall assemblies 12, lids 20 and base members 22. FIG. 27illustrates a kit of these components on a pallet 714. As shown in FIG.27, the respective pluralities of side wall assemblies 12, lids 20 andbase members 22 can be stacked on top of one another on pallet 714,thereby facilitating the shipment and rapid deployment, if desired, ofthese modular components of construction blocks 10. Each lid 20 can nestwithin an adjacent lid 20.

FIG. 28 illustrates two of the side wall assemblies 12, designated 12 aand 12 b, connected to one another. Assemblies 12 a and 12 b can beconnected to one another using a pair of connecting members 14 andfasteners 16, 18, or by any other suitable means. The holes to receivebolts 16, or the like, can be pre-drilled or drilled in the field. Inone alternate embodiment, a common panel can be provided to connectadjacent side wall assemblies 12 a and 12 b. The common panel caninclude two sets of female hinge members on each side to permit hingedlyconnecting the common panel to each adjacent panel of side wall assembly12 a and to permit hingedly connecting the common panel to each adjacentpanel of side wall assembly 12 b.

FIG. 29A illustrates three base members 22, designated 22 a, 22 b and 22c that can be used to construct a portion of a base layer 720 of thewall 702. As shown in FIG. 29A, base members 22 a, 22 b and 22 c can bepositioned adjacent one another, and can be positioned in abuttingrelationship with one another, but are not connected to one another inthe embodiment shown in FIG. 29A. Base members 22 a, 22 b and 22 c canbe generally parallel to one another as shown in FIG. 29A.

FIGS. 29B and 29C illustrate examples of alternate angular orientationsthat can be achieved between adjacent base members such as base members22 b and 22 c. As may be appreciated, when each base member 22 forms aportion of two octagons, as shown in FIGS. 29B and 29C, adjacent basemembers 22 can be oriented in 45° increments relative to one another.FIG. 29B illustrates base member 22 c at a 45° angle relative to basemember 22 b, while FIG. 29C illustrates base member 22 c at a 90° anglerelative to base member 22 b. It may be appreciated that base membershaving different numbers of sides and configurations can achieve angularorientations between adjacent base members in different angularincrements. In view of the many possible orientations and configurationsof base members, walls and other structures can be constructed with awide variety of shapes.

FIG. 30 illustrates a portion of the base layer 720 of wall 702, withthe side wall assembly 12 a releasably engaged with base member 22 a andthe side wall assembly 12 b releasably engaged with the base member 22b. The lower end flanges 34 of panels 24 of side wall assembly 12 a canbe received within one of the lower side wall receptacles 86 of basemember 22 a. One or more of the flanges 34 of side wall assembly 12 acan frictionally engage the lower boundary flange 84 of base member 22a. Similarly, the lower end flanges 34 of panels 24 of side wallassembly 12 b can be received within one of the lower side wallreceptacles 86 of base member 22 b. One or more of the flanges 34 ofside wall assembly 12 b can frictionally engage the lower boundaryflange 84 of base member 22 b. As may be appreciated, the set of sidewall assemblies 12 a, 12 b interconnect the base members 22 a, 22 b ofthe base layer 720 of wall 702. Flange 34 of panel 24 can be offsetinwardly from the outer surface 38 by a distance that is equal to a wallthickness of the lower boundary flange 84 of base member 22. Thispermits an outer surface of flange 84 to be flush with the outer surface38 of the central portion 30 of panel 24 when panels 24 engage basemember 22. Flange 32 of panel 24 can be offset inwardly from the outersurface 38 of the central portion 30 of panel 24 by a distance that isequal to a wall thickness of the upper boundary flange 98 of lid 20.This permits an outer surface of flange 98 to be flush with the outersurface 38 of the central portion 30 of panel 24 when panels 24 engagelid 20. One or more of the flanges 32 can frictionally engage the upperboundary flange 98 of lid 20. Configuring flanges 32 and 34 as describedabove can facilitate positioning lids 20 adjacent one another and basemembers 22 adjacent one another without creating gaps in wall 702.

FIG. 31 further illustrates the construction of the base layer 720 ofwall 702 and illustrates a portion of a second layer 730 of wall 702which is disposed on top of, and interconnected with, the base layer 720of wall 702. As shown in FIG. 31, a lid 20 a can be placed on top of,and releasably engaged with, the side wall assemblies 12 a and 12 b,which can be connected to one another. The central portions 104 of thetwo protrusions 102 of lid 20 a can be removed, leaving a pair of theapertures 105. Accordingly, apertures 105 can communicate with the loadchamber 70 of side wall assemblies 12 a, 12 b, which, in combinationwith the configuration of base members 22 a and 22 b, permits the loadchambers 70 of assemblies 12 a, 12 b to communicate with the respectiveload chambers of layer 730. A wide variety of materials can be used asballast material 740 as subsequently described. The ballast material canbe added during any stage of the construction of wall 702. As shown inFIG. 31, a base member 22 d of the second layer 730 of wall 702 can beinstalled that can releasably engage lid 20 a of the first layer 720.One of the protrusions 102 of lid 20 a can be nested within one of therecessed ledges 92 of base member 22d.

FIG. 32 further illustrates the construction of the base layer 720 andthe second layer 730 of wall 702. A base member 22 c can be added tobase layer 720 and can be positioned adjacent to base member 22 b, andcan abut base member 22 b. A second set of side wall assemblies 12 c and12 d can be added to the base layer 720. Side wall assemblies 12 c and12 d can be connected to one another as shown previously in FIG. 28 withrespect to side wall assemblies 12 a and 12 b, or by any other suitablemeans. Side wall assembly 12 c can be releasably engaged with basemember 22 b and side wall assembly 12 d can be releasably engaged withbase member 22 c, which interconnects base members 22 b and 22 c. A lid20 b can be added to the first layer 720 of wall 702, and lid 20 b canbe releasably engaged with side wall assemblies 12 c and 12 d.

A base member 22 e can be added to the second layer 730 of wall 702, andthe base member 22 e can be releasably engaged with lids 20 a, 20 b ofthe first layer 720 of wall 702, thereby interconnecting lids 20 a, 20b. A set of side wall assemblies 12 e and 12 f can be added to thesecond layer 730, which can be connected to one another in the mannerdescribed previously with respect to assemblies 12 a, 12 b. Assembly 12e can be releasably engaged with base member 22 d of layer 730 andassembly 12 f can be releasably engaged with base member 22 e of layer730, thereby interconnecting base members 22 d, 22 e.

The methodology described above with reference to FIGS. 28-32 can berepeated as required to complete the construction of the base layer 720and the second layer 730 of wall 702, as well as any layers of wall 702positioned above layer 730. The lids 20 of the top layer of wall 702 canbe closed, i.e. they can include the solid portions 104. Theinterconnection between adjacent layers of wall 702, such as layers 720and 730, as well as the interconnection of components within each layer,permits wall 702 to flex or deflect as a unit, which can facilitate theabsorption of a shock wave from an explosive ordinance.

In other embodiments, structures can be constructed using somewhatdifferent methodologies than that discussed with reference to FIGS.28-32 and using different combinations of construction block componentsto achieve structures having different configurations. For example, inanother embodiment a wall can be constructed that is the same as wall702 except as follows. Instead of the lids 20 and base members 22 beingstaggered relative to one another between adjacent layers of the wall asshown in FIG. 32, the lids 20 and base members 22 can be aligned withone another, with the base members 22 of the upper layer of an adjacentpair of layers of the wall being releasably engaged with respective lids20 of the lower layer of the adjacent pair of layers. In thisembodiment, sets of side wall assemblies 12, for example two connectedside wall assemblies 12 would interconnect two adjacent base members 22for each layer of the wall in the manner shown for wall 702, in FIG. 32.

FIG. 33 illustrates a wall 750 according to another embodiment that canbe the same as wall 702 except as follows. A base layer 752 and a secondlayer 754 of wall 750 can be the same as base layer 720 and the secondlayer 730, respectively, of wall 702 except as follows. Base layer 752does not include the lids 20 a and 20 b shown in FIG. 32 and can beconstructed without any other lids 20. The second layer 754 does notinclude base members 22 d and 22 e can be constructed without any otherbase members 22. Instead, structure 750 can include a plurality ofhybrid members 756 that can serve as both lids for the base layer 752and base members for the second layer 754. This is illustrated withrespect to hybrid members 756 a and 756 b. Hybrid member 756 a isreleasably engaged to the side wall assembly 12 a of base layer 752 andside wall assembly 12 e of the second layer 754. Hybrid member 756 b isreleasably engaged with side wall assembly 12 b of base layer 752 andside wall assembly 12 f of the second layer 754. Side wall assemblies 12e and 12 f can be connected to one another as shown in FIG. 33 which caninterconnect the hybrid members 756 a and 756 b.

Hybrid member 756 can include features of lid 20 and base member 22. Forexample, hybrid member 756 can include a boundary flange 758 that can beconfigured the same as the lower boundary flange 84 of base member 22and the upper boundary flange 98 of lid 20 and can have a thickness thatcan be the same as the combined thickness of flanges 84 and 98.

Hybrid member 756 has a lower surface (not shown) that can be configuredthe same as the lower surface 96 of lid 20. The lower surface and flange758 of hybrid member 756 can cooperate to define a plurality of upperside wall receptacles, which can be a pair of upper side wallreceptacles, with each being configured to receive one of the side wallassemblies 12.

Hybrid member 756 has an upper surface 780 that can be configured thesame as the upper surface 80 of base member 22. The upper surface 780and flange 758 can cooperate to define a plurality of lower side wallreceptacles, which can be a pair of lower side wall receptacles, witheach being configured to receive one of the side wall assemblies 12.

Hybrid member 756 can include a plurality of apertures 790 (one shownfor each of the hybrid members 756 a, 756 b), which can be a pair ofapertures 790. Apertures 790 extend through hybrid member 756 and permitcommunication between aligned ones of the load chambers 70 of verticallyadjacent side wall assemblies such as side wall assemblies 12 a and 12e. If base member 22 a and hybrid member 756 a are disposed at an end ofbase layer 752 of wall 750, a single side wall assembly 12 (not shown)can be releasably engaged with both base member 22 a and hybrid member756 a to complete that end of the base layer 752. A similar approach canbe taken if required for the opposite end of base layer 752 and for eachend of other layers of wall 750. Lids 20 can be used to cap the toplayer of wall 750. Hybrid member 756 can be made of the same materialsand can be formed using the same processes as those described previouslyfor lid. 20 and base member 22.

FIG. 34 illustrates a structure 760 according to another embodiment.Structure 760 includes a first layer 762 that includes two constructionblocks, designated 10 m and 10 n, which are positioned side-by-side.Blocks 10 m and 10 n can be positioned in abutting relationship with oneanother but are not interconnected in one embodiment. The twoprotrusions 102 of lids 20 m and 20 n (only one protrusion 102 of lid 20m and one protrusion of lid 20 n shown) of blocks 10 m and 10 n,respectively, each have an aperture 105 in lieu of the solid centralportion 104, which permits the load chambers 70 of blocks 10 m and 10 nto communicate with respective load chambers 70 of a second layer 764 ofstructure 760. The second layer 764 can include a construction block 10p that is disposed on top of and releasably engaged with constructionblocks 10 m and 10 n, which interconnects blocks 10 m and 10 n.

For purposes of illustration, the lid 20 p of the second layer 764 isshown with one solid central portion 104 and one aperture 105. Ifstructure 760 includes additional layers of blocks 10, then the lid 20 pcan include two of the apertures 105. If layer 764 is the lop layer ofstructure 760, then lid 20 p can include two of the solid centralportions 104. Layers 762 and 764 can include additional blocks 10 andstructure 760 can include additional layers above layer 764. Theremainder of structure 760 can be constructed as described above, sothat the blocks 10 of each layer are staggered, or offset, with respectto the blocks 10 of each adjacent layer in a manner that is similar tothe typical arrangement of bricks in a wall having multiple layers orcourses. The load chambers 70 of each block 10, of each layer, cancommunicate with respective load chambers 70 of blocks 10 of otherlayers and the load chambers 70 of the base layer 762 can communicatewith the surface upon which structure 760 rests, which can providesupport (or the columns of ballast material 740.

In another embodiment, a structure (not shown) can be constructed thatis the same as structure 760 shown in FIG. 34 except that the blocks 10of vertically adjacent layers are aligned with one another instead ofbeing staggered or offset from one another. For example, this could beaccomplished by re-positioning block 10 p of layer 764 so that it is ontop of and aligned with block 10 m of base layer 762. The remainder ofbase layer 762 and the second layer 764, as well as any other layers,could be constructed in this manner. This configuration can facilitatereplacing a construction block 10 of any layer below the top layer, forexample base layer 762. In this configuration the adjacent side wallassemblies 12 of adjacent blocks 10, within the same layer of the wall,could be connected to one another to enhance the stability of the wall.It may be appreciated that each adjacent pair of side wall assemblies12, within the same layer of any structure, can be connected to oneanother to enhance the stability of the structure. Also while the sidewall assemblies 12 of the same construction block 10 can beinterconnected as described previously, a direct connection betweenadjacent side wall assemblies 12 of the same construction block 10 canbe omitted, with the side wall assemblies being interconnected by acommon base member 22 and a common lid 20. The configuration describedabove, with blocks of vertically adjacent layers aligned with oneanother, can also facilitate providing a stair-step configuration on oneor both ends of the wall if required to accommodate changes in theterrain, in either an upward or downward direction as required. Forexample, in such a configuration, block 10 n could be moved upward ordownward as required relative to blocks 10 m of base layer 762 and block10 p of the second layer 764, to accommodate a change of slope of theterrain upon which the wall is constructed. The block 10 n could beconnected to one or both of the blocks 10 m and 10 p. It may beappreciated that walls having other configurations can includestair-step portions as required.

FIG. 35 illustrates a construction block 800 according to anotherembodiment. Construction block 800 includes two side wall assemblies802, a lid 804 and a base member 806. The side wall assemblies 802 canbe releasably engaged with lid 804 and base member 806. This can beaccomplished with protrusions (not shown) and mating receptacles (notshown) at the interfaces of the side wall assemblies 802 with lid 804and base member 806, or by other suitable means.

FIG. 36 illustrates the two side wall assemblies 802 after finalforming. The side wall assemblies 802 can be formed by molding a strip808 (FIG. 37) of panels 810 that are hingedly interconnected. Strip 808,as well as lid 804 and base member 806 can be molded from any of thethermoplastic materials discussed previously for the components ofconstruction block 10. Each of the panels 810 can be connected to eachadjacent one of the panels 810 by a living hinge 812. FIGS. 39A-39Fillustrate a sequence of steps that can be used to fold the strip 808 ofpanels 810 into the two side wall assemblies 802 shown in FIGS. 35, 36and 39F. Each side wall assembly 802 defines a hollow load chamber 814having an open top 816 and an open bottom 818 (FIG. 36).

The strip 808 of panels 810 can include a plurality of tabs 820, orsimilar protrusions, at one end and mating apertures 822 at the oppositeend as shown in FIG. 37 (not shown in other Figs.). Tabs 820 can engage(not shown) apertures 822 when the side wall assemblies 802 are formedas shown in FIG. 36. As shown in FIGS. 36 and 39F, after final formingof strip 808, two of the panels 810 are side-by-side and separate thetwo load chambers 814. The strip 808 of panels 810 can include aweakened, or “blowout” section 824 that can be defined by perforationsin the panels 810 or by other suitable means. If the block 800 isexposed to a blast wave, the force exerted on the block 800 can,depending upon the magnitude and direction of the force, cause the twopanels 810 that are side-by-side to rupture the “blowout” section 824,which can relieve the blast pressure.

Blocks 800 can be used alone or in combination with one another to formvarious structures. For example multiple blocks 800 can be disposedadjacent to one another to form a base layer of a structure and blocks800 of other layers can be staggered with the blocks of adjacent layers,in the manner illustrated and described with respect to FIG. 34.

FIG. 40 illustrates a construction block 900 according to anotherembodiment. Construction block 900 includes two collapsible side wallassemblies 912, a lid 920 and a base member 922. Each collapsible sidewall assembly 912 can include a plurality of hingedly interconnectedpanels 924. The side wall assemblies 912 can be movable betweencollapsed and erected configurations, in which the side wall assemblies912 releasably engage lid 920 and base member 922. The outer surfaces938 of a central portion 930 of the panels 924 of each side wallassembly 912 can cooperate to define a polygon when viewed in transversecross-section in the erected configuration, similar to the view shown inFIG. 15 for one of the side wall assemblies 12. The polygon can be anoctagon, the same as shown in FIG. 15 for assembly 12. However, eachside wall assembly 912 can include sixteen of the panels 924 to definean octagon as compared to each side wall assembly 12 that can includeeight of the panels 24 to define an octagon.

Each side of the polygonal shape of side wall assembly 912 can beachieved with two of the panels 912, as illustrated with respect topanels 924 a and 924 b in FIG. 40. An octagonal shape can be achievedwith sixteen panels instead of eight due to the relative sizes of lid920, base member 922 and panels 924. As shown in FIG. 40, each of thepanels 924 a, 924 b can engage a single, generally linear portion 984 aof a lower boundary flange 984 of base member 922 and a single,generally linear portion 998 a of an upper boundary flange 998 of lid920.

A wide variety of structures can be built using components of block 900,i.e., side wall assemblies 912, lids 920 and base members 922, forexample by using any of the methodologies described previously. Sidewall assemblies 912, lid 920 and base member 922 can be made of the samematerials, and can be made using the same manufacturing processes, asthose discussed previously with respect to the side wall assemblies 12,lid 20 and base member 22 of construction block 10.

FIG. 41 illustrates a construction block 1000 according to anotherembodiment. Construction block 1000 includes two collapsible side wallassemblies 1012, a lid 1020 and a base member 1022. Side wall assemblies1012 can be the same as side wall assemblies 12 described previouslywith respect to construction block 10. Accordingly, each side wallassembly 1012 can include a plurality of hingedly interconnected panels1024 and side wall assemblies 1012 can be movable between a collapsedconfiguration (not shown) and an erected configuration in which the sidewall assemblies 1012 can releasably engage lid 1020 and base member 1022as shown in FIG. 41.

Lid 1020 can be the same as lid 20 of block 10 except as follows. Lid1020 can include a handle 1050, which facilitates handling and/orcarrying lid 1020. Handle 1050 can include a recessed portion 1052formed in an upper boundary flange 1098 and an aperture 1054 that canextend through lid 1020 from an upper surface 1094 through a lowersurface (not shown). As shown in FIG. 41, the recessed portion 1052 caninclude first and second diagonal sides and a third side connecting thediagonal sides. However, the recessed portion 1052 can have shapes otherthan that shown. Also, aperture 1054 can have a variety of shapes otherthan the generally triangular shape shown in FIG. 41.

Base member 1022 can be the same as base member 22 of construction block10 except as follows. Base member 1022 can include a handle 1055, whichfacilitates handling and/or carrying base member 1022. Handle 1055 caninclude a recessed portion 1057 formed in a lower boundary flange 1084and an aperture 1059 that can extend through base member 1022 from alower surface (not shown) through an upper surface 1080 of base member1022. As shown in FIG. 42, the recessed portion 1057 can include firstand second diagonal sides and a third side connecting the diagonalsides. However, the recessed portion 1057 can have shapes other thanthat shown. Also, aperture 1059 can have a variety of shapes other thanthe generally triangular shape shown in FIG. 41.

The components of construction block 1000, i.e. side wall assemblies1012, lid 1020 and base member 1022 can be made of the same materialsand can be made using the same processes as those described previouslywith respect to side wall assemblies 12, lid 20 and base member 22,respectively, of construction block 10. A wide variety of structures canbe built using the components of construction block 1000, for example byusing any of the methodologies described previously.

Structures according to the inventive principles can include roofedshelters. For example, one or more walls such as walls 702, 704, 706,708, 710 and 712 shown in FIG. 26, can partially or completely surroundan area and a roof can be placed on lop of the walls to provide atemporary shelter for personnel, for example. The roof can beconstructed from conventional roofing materials and/or a plurality ofinterconnected panels, for example panels 24. Depending upon the lengthand width of the roof, which can be flat, various structural members maybe required to reinforce the roof. To provide further protection of aflat roof, one or more construction blocks (e.g., 10) can be placed ontop of the roof. The roof can also be sloped or have an “A-frame”configuration.

Construction blocks and structures, such as various walls, revetmentsand other structures, according to the inventive principles can havesuperior blast mitigation and ballistic protection features andtherefore can protect against multiple-type attacks including, but notlimited to: high-explosive ordinance (HE);improvised explosive devices(IEDs); rocket propelled grenades (RPGs) and other grenades; mortars;small arms ammunition and other kinetic energy weapons; shrapnelincluding that from an explosive ordinance and secondary shrapnel, forexample that is caused by an exploding concrete barrier or wall.Protection can be provided against shock waves, projectiles andfireballs created by the ordinance. Additionally, personnel and assetprotection can be provided with regard to other threats, such as rammingvehicles and environmental conditions.

In view of the foregoing, it may be appreciated that the constructionblocks and structures can be particularly useful in war zones or areasoutside of war zones that are subject to multiple-type attacks. Examplesof military applications include, but are not limited to, the following:base camp and command post protection; perimeter security for buildingsand a wide variety of other assets, for example munitions, communicationcenters, fuel depots, aircraft and many others; construction of fightingpositions; repair of damaged structures; hardening of “soft” areas, forexample tents and other temporary structures; revetments and trafficcheck point protection.

The construction blocks and structures can also have a wide variety ofgovernment, commercial and private sector applications such as toprovide protection from multiple-type attacks, such as that describedpreviously, or ramming vehicles, for example, and to provide protectionagainst naturally occurring phenomenon, for example high winds andflooding caused by hurricanes.

Other examples of government, commercial and private sector applicationsinclude, but are not limited to: perimeter security for variousgovernment buildings, for example stale embassies; perimeter securityfor historic landmarks; perimeter security for various commercialbuildings of particular importance, for example financial institutions;and security in areas attracting large numbers of people, for examplevarious sporting venues. Other applications can include disaster reliefwalls and shelters, flood mitigation, roadway construction barriers andretaining walls, and motorsport racing collision protection.

The construction blocks and a wide variety of structures, that caninclude walls, revetments and other structures, that can be constructedfrom kits of components of the construction blocks, can exhibit manyadvantageous features. The shape and material characteristics ofconstruction blocks and structures according to the inventive principlescan synergistically combine with the ballast fill material to dissipateblast energy so that shock waves, peak overpressure, reflectedoverpressure, impulse, and chemical (after-burn) effects aresignificantly reduced. Mitigating these effects will in turn reduce theoverall size of the blast envelope, resulting in reduced “stand-off”distances thereby increasing survivability.

The laws of conservation of mass, momentum and energy for a shock waveimply that it is difficult to reduce explosive effects rapidly. Althoughsome energy can be absorbed through deformation, conventional hard andflat walls used for protection against explosive ordinance can have thenegative effect of reflecting a blast wave, which can magnify the blasteffect. Reflected energy can be a significant problem, particularly inconfined spaces where impinging shock waves reflecting off of thesurface of the flat wall can add to the incident shock wave to create adestructive synergism of much greater gas density, temperature, pressureand overpressure duration, which all contribute to the impulse, orpiston. The multi-faceted surfaces of the construction block, walls andother structures according to the inventive principles can mitigate thisnegative synergistic effect, resulting in superior blast mitigationcharacteristics. When a force acts perpendicular to a surface, thepressure (p) exerted is the ratio between the magnitude of the force (f)and the area (a) of the surface; p=f/a. Multi-faceted walls according tocertain embodiments can increase the overall area (a) exposed to theblast for a wall having a particular height and length, which accordingto laws of physics can attenuate the overall pressure exerted on thesurface of the structure.

Also, walls according to certain embodiments can have an interlockingconstruction between adjacent layers or courses in certain embodimentsand both within each layer and between adjacent layers in certain otherembodiments, which can allow the wall to flex or deflect as a unit thatcan attenuate the blast wave.

Progressive collapse is the collapse of all or part of a structurenormally precipitated by damage or failure of a relatively small part ofit. If one or more portions of structures built with construction blocksare damaged such that ballast material escapes from an affected lowerportion, aligned ones of the load chambers of the structure above theaffected layer can gravity feed ballast material downward andredistribute it vertically to the affected lower area, which can providea progressive collapse resistant feature.

The multi-faceted surfaces of walls, according to certain embodiments,can also trap shrapnel, for example in the spaces between adjacentpanels of the side wall assemblies, which can be angled relative to oneanother. Having angled panels exposed to penetrating blast effects andkinetic energy projectiles can provide enhanced protection with noadditional cost in material or weight. For example, if a potentiallypenetrating projectile enters at an angle other than 90°, it must passthrough more material than when impacting a wall disposed at a 90° anglerelative to the path of the projectile. Additionally, projectilesarriving at a glancing or grazing angle can “skid” across thecorresponding ones of the multi-faceted surfaces before penetrating thesurface, causing the projectiles to alter trajectory and lose kineticenergy, thereby enhancing the ballistic protection features of the wall.This effect can be enhanced further by the materials of construction ofthe construction block components described previously and by a coatinghaving a rough texture when used.

The materials of construction can also provide anti-fragmentationadvantages as compared to other materials such as concrete, steel andother material used in conventional protective structures, which canhave the negative effective of multiplying shrapnel. For example, whenABS is used, the included “rubber-like” butadiene component can provideanti-fragmentation advantages. It should be understood that othermaterials of construction that can be used, for example high impactplastics, can also provide anti-fragmentation advantages. Also, thematerial of construction, for example ABS, can have a “self-healing”characteristic if a projectile passes through one of the panels of theside wall assemblies. The heat resulting from the projectile impactingthe panel can cause a thermoplastic material, such as ABS, surroundingthe entrance hole to re-melt and/or deform such that the entrance holecan be at least partially closed that can facilitate retaining ballastmaterial.

The materials of construction of the construction block components canbe resistant to heat, cold, UV rays and water and provide superiorstrength, hardness, creep and wear properties, for example whenthermoplastic materials are used. As yet another advantage, thematerials of construction permit cost effective manufacturing and resultin lightweight components. For example, when base members, lids andpanels according to the inventive principles are made of a thermoplasticmaterial, they can be formed by injection molding or they can bethermoformed. Also, the panels can be extruded.

The lightweight and modular construction of the structural componentsaccording to the inventive principles permits these components to beportable and rapidly deployable. For example, the side wall assemblies12 can be collapsed and stacked on top of one another on a pallet asshown in FIG. 27. The lids 20 can also be stacked on a pallet, with eachlid nested within an adjacent lid. The base members 22 can also bestacked on the pallet. Pallets supporting the structural components canbe shipped by conventional means of transportation to the points ofdestination. When the situation requires, such pallets can be deployedby parachute or lowered into position by a helicopter in areas that aredifficult to access.

The modular base members, side wall assemblies and lids according to theinventive principles permit structures to be easily and quicklyassembled, without the use of a skilled workforce. This modular featurealso facilitates disassembly of the structure when desired. Also, thestructures can be assembled with or without the use of heavy equipment,which can be required to build some conventional protective structures.Unlike some conventional structures that can have a “stepped”configuration with vertically adjacent layers offset from one another,structures according to the inventive principles can include verticalwalls without such steps thereby making it more difficult for hostileforces to scale the walls. Also, because walls according to theinventive principles are rigid, the walls are resistant to drooping orsagging over time as is common for certain conventional structures.

Some conventional structures are made either entirely. or partially ofconcrete, which requires time to cure that can be undesirable inemergency situations. Concrete is expensive and can be difficult toacquire and transport. Furthermore, the use of concrete requiressignificant labor and resources, as well as machinery requiring askilled work force. Although, the load chambers included in structuresaccording to the inventive principles can be filled with concrete, otherballast materials can be used to fill the load chambers that do notrequire a cure time. In fact, virtually any material can be used as aballast material to fill the load chambers, including those that arereadily available on site. Accordingly, it is not necessary to locate ormanufacture special ballast material. Examples of ballast material thatcan be used to fill the load chambers, include but are not limited tothe following materials: dirt, sand, mud, salt, gravel, rocks, ice,snow, water, ceramics, and stabilized injectable aluminum foam such asCymat™. Also, pumice or other extinguishing materials can be used asballast to provide protection against fire balls from a blast. As may beappreciated, load chambers can be filled with the foregoing, or other,ballast materials without the use of machinery, if none is readilyavailable.

As yet another advantage, adjacent side wall assemblies can includepanels having generally planar outer surfaces that are generallyparallel to one another, which can facilitate the attachment ofsecondary structures such as metal guard rails typically seen alongroadways, plywood, drywall or other building materials to the side wallassemblies. For example, this can be achieved with the adjacent sidewall assemblies of construction blocks 10, 800, 900 and 1000 describedpreviously. However, it may be appreciated that this can also beachieved with blocks having side wall assemblies with different numbersof sides created by the included panels. The attachment of drywall orother building materials to the side wall assemblies to create asecondary structure can be done for a variety of reasons including theconcealment of the protective structure to avoid signaling hostileforces of the existence of such a structure and a potentially high valuetarget protected by the structure. Secondary structures can also be usedto provide decoration and insulation. Further with regard to secondarystructures, the hollow load chambers of the primary protective structure(e.g., prior to filling with ballast material) can be used to routeelectrical wiring, plumbing, communication cables and HVAC conduit ofthe secondary structure and can also receive reinforcement members suchas rebar.

Construction blocks according to the inventive principles can bevirtually any color and can include various patterns, for examplecamouflage in war zone applications or stripes when used in roadwayapplications, or any other desirable indicia applied to various surfacesof the construction blocks. It may be appreciated that the constructionblocks and structures assembled from components of the constructionblocks according to the inventive principles, can provide advantages inaddition to those discussed herein.

While the inventive principles have been illustrated by the descriptionof various embodiments thereof, and while the embodiments have beendescribed in considerable detail, it is not intended to restrict or inany way limit the scope of the appended claims to such detail.Additional advantages and modifications will be readily apparent tothose skilled in the art. The invention in its broader aspects istherefore not limited to the specific details, representative apparatusand methods and illustrative examples shown and described. Accordingly,departures may be made from such details without departing from thescope or spirit of the general inventive concept.

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 40. A method of building a modular structure,the method comprising: providing a kit of construction block componentscomprising a plurality of base members and a plurality of side wallassemblies, each of the side wall assemblies comprising a plurality ofhingedly interconnected panels, each of the side wall assemblies beingmovable between a collapsed configuration and an erected configuration,wherein each of the side wall assemblies define, in the erectedconfiguration, a hollow load chamber having an open top and an openbottom; constructing a first plurality of sets of the side wallassemblies, each of the first plurality of the sets of the side wallassemblies comprising at least two of the side wall assemblies in theerected configuration and connected to one another; and building a baselayer of the structure comprising: arranging a first plurality of thebase members of the kit adjacent to one another on a support surface;and releasably engaging each of the first plurality of the sets of theside wall assemblies with a respective adjacent pair of the firstplurality of the base members.
 41. The method of claim 40, wherein:providing the kit further comprises providing a plurality of lids; andbuilding the base layer of the structure further comprises arranging afirst plurality of the lids such that each of the first plurality of thelids releasably engages a respective one of the first plurality of thesets of the side wall assemblies of the base layer.
 42. (canceled) 43.The method of claim 41, wherein: each of the base members of the kitdefines a plurality of lower side wall receptacles; and each of the sidewall assemblies of each of the first plurality of the sets of the sidewall assemblies is received by a respective one of the lower side wallreceptacles defined by a respective one of the first plurality of thebase members.
 44. The method of claim 43, wherein: each of the lids ofthe kit comprises a lower surface and an upper boundary flangecooperating with the lower surface to define a pair of upper side wallreceptacles; and each of the side wall assemblies of each of the firstplurality of the sets of the side wall assemblies of the base layer isreceived within a respective one of the upper side wall receptacles of arespective one of the first plurality of the lids.
 45. The method ofclaim 40, further comprising: at least partially filling at least someof the load chambers of the base layer with ballast material. 46.(canceled)
 47. The method of claim 40, wherein: each of the base membersof the kit, each of the side wall assemblies of the kit and each of thelids of the kit comprise a thermoplastic material.
 48. (canceled) 49.(canceled)
 50. (canceled)
 51. (canceled)
 52. (canceled)
 53. (canceled)54. (canceled)
 55. (canceled)
 56. The method of claim 40, wherein: eachof the panels of each of the side wall assemblies of the kit comprisesfirst and second sides and a central portion extending between the firstand second sides, the central portion having an inner surface and agenerally planar outer surface, the generally planar outer surfaces ofat least some of the panels of each of the side wall assemblies, when inthe erected configuration, being angled relative to one another.
 57. Themethod of claim 56, wherein for each respective one of the side wallassemblies of the kit, when viewed in transverse cross-section and whenthe side wall assembly is in the erected configuration: the generallyplanar outer surfaces of the central portions of the panels cooperate todefine a polygon.
 58. The method of claim 57, wherein: the polygon is anoctagon.
 59. The method of claim 57, wherein: each of the panels of eachof the side wall assemblies of the kit further comprises a first endflange and a second end flange; and for each of the panels of each ofthe side wall assemblies of the kit, the central portion of the panelextends between the first end flange and the second end flange, thefirst end flange and the second end flange being offset inwardly fromthe generally planar outer surface of the central portion.
 60. A methodof building a modular structure, the method comprising: providing a kitof construction block components comprising a plurality of base members,a plurality of lids and a plurality of side wall assemblies, each of theside wall assemblies comprising a plurality of hingedly interconnectedpanels, each of the side wall assemblies being movable between acollapsed configuration and an erected configuration, wherein each ofthe side wall assemblies define, in the erected configuration, a hollowload chamber having an open top and an open bottom; constructing a firstplurality of sets of the side wall assemblies, each of the firstplurality of the sets of the side wall assemblies comprising at leasttwo of the side wall assemblies in the erected configuration andconnected to one another; and building a base layer of the structurecomprising: arranging a first plurality of the base members of the kitadjacent to one another on a support surface; releasably engaging eachof the first plurality of the sets of the side wall assemblies with arespective adjacent pair of the first plurality of the base members; andarranging a first plurality of the lids of the kit such that each of thefirst plurality of the lids releasably engages at least one of the firstplurality of the sets of the side wall assemblies.
 61. The method ofclaim 60 further comprising: building a second layer of the structure ontop of, and releasably engaged with, the base layer of the structure,wherein building the second layer comprises: arranging a secondplurality of the base members of the kit such that each of the secondplurality of the base members releasably engages at least one of thefirst plurality of the lids of the base layer.
 62. The method of claim61, wherein: arranging the first plurality of the lids of the base layerfurther comprises positioning the first plurality of the lids such thateach of the first plurality of the lids releasably engages a respectiveadjacent pair of the first plurality of the sets of the side wallassemblies.
 63. The method of claim 62, wherein: arranging the secondplurality of the base members of the second layer further comprisespositioning the second plurality of the base members such that each ofthe second plurality of the base members releasably engages a respectiveadjacent pair of the first plurality of the lids of the base layer. 64.The method of claim 63, wherein: each of the lids of the kit comprises alower surface and an upper boundary flange cooperating with the lowersurface to define a pair of upper side wall receptacles; and each of theside wall assemblies of each of the first plurality of the sets of theside wall assemblies of the base layer is received within a respectiveone of the upper side wall receptacles of a respective one of the firstplurality of the lids.
 65. The method of claim 64, wherein: each of thebase members of the kit further comprises a lower surface defining aplurality of recessed ledges, each of the recessed ledges having a firstshape, and wherein each of the lids of the kit further comprises anupper surface and a plurality of protrusions extending upwardly from theupper surface, each of the protrusions having a second shape that iscomplementary to the first shape of the recessed ledges of the basemembers; and building the second layer further comprises nesting each ofthe protrusions of each of the first plurality of the lids of the baselayer within a respective recessed ledge of a respective one of thesecond plurality of the base members of the second layer.
 66. The methodof claim 65, further comprising: constructing a second plurality of setsof the side wall assemblies, each of the second plurality of the sets ofthe side wall assemblies comprising at least two of the side wallassemblies in the erected configuration and connected to one another;wherein building the second layer of the structure further comprisesreleasably engaging each of the second plurality of the sets of the sidewall assemblies with a respective adjacent pair of the second pluralityof the base members.